MHG Heating ProCon 16 Manuel utilisateur

MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR

Telephone 08456 448802 Fax 08456 448803 Email info@mhgheating.co.uk Web www.mhgheating.co.uk

010114

Installation and Operating Manual for the

ProCon 16, 27, 47, 75 & 77

Wall Mounted Condensing Boiler Range.

(RVS 43 Cascade Models)

MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR

Telephone 08456 448802 Fax 08456 448803 Email info@mhgheating.co.uk Web www.mhgheating.co.uk

010114

Section

Page #

1.0

Appliance Type

1.1

ProCon H

1.2

ProCon S

1.3

ProCon HS

1.4

ProCon HS+

1.5

ProCon HM

2.0

Installation Regulations and Requirements

2.1

Appliance Warranties. Supplied Components.

3.0

Dimensions 16, 27 & 47

3.1

Dimensions 75

3.2

Dimensions 77

3.3

Dimensions Kompact (For Information only)

3.4

Installation Clearances and Mounting Information 16, 27 & 47

3.5

Installation Clearances and Mounting Information 75

3.6

Installation Clearances and Mounting Information 77

4.0

Delivery and Mobility

4.1

Case Removal

5.0

Technical Data

6.0

Pressure Relief Valve

7.0

Electrical Connections

8.0

Hydraulic and Wiring Guide Single Unit Option 1 (Heating Only) (Low Resistance Circuit)

8.1

Hydraulic and Wiring Guide Single Unit Option 2 (Heating & HWS) (External 3 Way Valve)

8.2

Hydraulic and Wiring Guide Single Unit Option 3 (Heating & HWS) (HS)

8.3

Hydraulic and Wiring Guide Single Unit Option 4 (Heating Only) (High Resistance Circuit)

8.4

Hydraulic and Wiring Guide Single Unit Option 5 (Heating & HWS) (High Resistance Circuit)

8.5

Hydraulic and Wiring Guide Single Unit Option 6 (Heating & HWS) (Two Heating Circuits)(HS)

8.6

Hydraulic and Wiring Guide Single Unit Option 7(Heating & HWS) (Two Heating Circuits)

8.7

Hydraulic and Wiring Guide Single Unit Option 8 (Heating & HWS) (Two Heating Circuits)(Mixing)(HS)

8.8

Hydraulic and Wiring Guide Single Unit Option 9 (Heating & HWS) (Two Heating Circuits)(Mixing)

8.9

Hydraulic and Wiring Guide Single Unit Option 10 (Heating & HWS) (Two Heating Circuits)(RVA63)

8.10

RVA63 Zone Controller Wiring Information

8.11

Hydraulic and Wiring Guide Multiple Units Option 11 (Heating & HWS) (RVS43 Cascade Manager )

8.12

RVS43 Cascade Manager Wiring Information (Controller Only)

8.13

RVS63 Cascade Manager Housing Wiring Information (Including Space For RVA46 Zone Controller)

8.14

Hydraulic and Wiring Guide Multiple Units Option 12 (Heating & HWS) (RVS43 Cascade Manager+RVA63)

9.0

BMS Interface Installation and Parameter Alteration & AGU Mixing Zone Clip Installation and Parameter Alteration

10.0

Fluing Options

10.01

MicroMat EC 60-75 Flue Adapter for use with ProCon 77

10.1

Single Unit Balanced Flue Wall Termination

10.2

Single Unit Balanced Flue Vertical Termination

10.2.5

Single Unit Balanced Flue with Concentric to Twin DN80 Products of Combustion and Combustion Air Ducts.

10.3

Single Unit open Flue Wall Termination

10.4

Single Unit Open Flue Vertical Termination

10.5

Cascaded Open Flue Vertical Termination

10.6

Dimensions of Available Flue Components

10.7

Balanced Flue Terminal Positions For Boilers below and Above 70kW Net Input

11.0

Filling The System

11.1

Pressure Vessel

12.0

System Water Quality

12.1

Care With The Use Of Solder Flux

13.0

Appliance Controls

13.1

Module Operating Codes

14.0

Appliance Fault Codes

14.1

Enhanced Appliance Fault Codes

15.0

Accessing Boiler Parameters (Control Parameter Default Settings)

16.0

RVS43 Cascade Manager General Information

16.1

RVS43 Cascade Manager Parameter Setting

17.0

Commissioning

17.1

Pre-Commissioning Checks.

17.2

Combustion System Commissioning

17.3

NG/LPG –LPG/NG Conversion Procedure

18.0

Routine Inspection and Servicing

18.1

Routine Service Inspection

18.2

Routine Cleaning and Maintenance

19.0

Weather Compensation Slope Graph

20.0

Optional System Controls

21.0

Internal Wiring Diagrams

21.1

Internal Wiring Diagrams 16, 27 & 47 H , HS & S

21.2

Internal Wiring Diagrams 47 H & S

21.3

Internal Wiring Diagrams 75 & 77 H

21.4

Internal Wiring Diagrams 75 & 77 HM

22.0

HM and Cascade Slave Units Equipped with OCI420 Communication Clips (LED Indication)

100

23.0

Exploded Spares Diagrams 16, 27 & 47

101

24.0

Exploded Spares Diagrams 75

107

25.0

Exploded Spares Diagrams 77

109

Notes

112

MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR

Telephone 08456 448802 Fax 08456 448803 Email info@mhgheating.co.uk Web www.mhgheating.co.uk

010114

1.0 Appliance TypeThere are four build types and four outputs within the ProCon range.

Please ensure you have the correct unit for the application and where required located correctly

within the cascade prior to beginning the installation.

ProCon 16H & 16HS, ProCon 27H, 27S & 27HS, ProCon 47H & 47S, ProCon 75&77H & 75&77HM

1.1 The ProCon H range of appliances is designed to be applied to systems requiring direct on

boiler weather compensated heating and priority hot water production via a separate high

recovery calorifier/cylinder.

1.2 The ProCon S range of appliances is designed to be applied to systems requiring direct on

boiler weather compensated heating and priority on demand hot water production via an internal

late heat exchanger.

1.3 The ProCon HS range of appliances are designed to be applied to systems requiring direct on

boiler weather compensated heating and priority hot water production via a separate high

recovery Calorifier/Cylinder, where the diverter valve controlling the production of hot water is

within the boiler case.

1.4 The ProCon HS+ can be supplied complete with an integrated high recovery calorifier for

simplified and attractive installation housed within and extended case. The high recovery calorifer

can be located beneath of adjacent to the boilers. (Further information available via the website

www.mhgheating.co.uk)

1.5 The ProCon HM appliance is supplied complete with and integral RVS43 Cascade Manager

capable of controlling an additional 11 ProCon boilers. Each subsequent boiler must be fitted with

an OCI420 Communication Clip.

The product codes for the entire range are:

Product Name

Product Code

ProCon 16 H

96.30000-7192

ProCon 16 HS

96.30000-7193

ProCon 27 H

96.30000-7194

ProCon 27 S

96.30000-7195

ProCon 27 HS

96.30000-7196

ProCon 47 H

96.30000-7197

ProCon 47S

96.30000-7198

ProCon 75 H

96.30000-7188

ProCon 75 HM

96.30000-7189

ProCon 77 H

96.30000-7190

ProCon 77 HM

96.30000-7191

MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR

Telephone 08456 448802 Fax 08456 448803 Email info@mhgheating.co.uk Web www.mhgheating.co.uk

010114

2.0 Installation Regulations and Requirements

The installation of ProCon HT boilers must be in accordance with the relevant requirements of Gas

Safety (Installation & Use) Regulations 1994, Health & Safety at Work Act, Building Regulations, IEE

Regulations, Construction (Design & Management) Regulations 1994, Local Authority Bye-Laws,

National, Fire Regulations and Insurance Company requirements.

The following Codes of Practice are also applicable:-

BS 5440-1: 2000 Installation of flues and ventilation for gas appliances of rated input not

exceeding 70 kW net (1st, 2nd and 3rd family gases).

Part 1: Specification for the installation of flues.

BS 5440-2: 2000 Installation of flues and ventilation for gas appliances of rated input not

exceeding 70 kW net (1st, 2nd and 3rd family gases).

Part 2: Specification for installation and maintenance of ventilation for gas appliances.

BS 5449: 1990 Specification for forced circulation hot water central heating systems for domestic

premises.

BS 6644: 2005 Specification for gas fired hot water boilers of rated inputs between 70kW (net)

and 1.8MW(net) (2nd and 3rd family gases).

BS 6798: 1987 Specification for installation of gas fired hot water boilers of rated input not

exceeding 60 kW.

BS 6880: 1988 Code of Practice for low temperature hot water heating systems of output greater

than 45kW. Parts 1, 2 & 3.

BS 6891: 1988 Specification for installation of low pressure gas pipework of up to 28mm (R1) in

domestic premises (2nd family gases)

BS 7593: 1992 Code of Practice for treatment of water in domestic hot water central heating

systems.

BS 7671: 1992 Requirements for electrical installations. IEE Wiring Regulations. Sixteenth edition.

CISBE Guide reference sections B7, B11 and B13.

CP342 Part 2: 1974 Code of Practice for centralized hot water supply.

GE/UP/2 Gas installation pipework, boosters and compressors on industrial and commercial

premises.

IGE/UP/4 Commissioning of gas fired plant on industrial and commercial premises

IGE/UP/10 Installation of gas appliances in industrial and commercial premises. Part 1: Flued

appliances.

And any addition prevailing regulation and or code of practice not detailed above.

MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR

Telephone 08456 448802 Fax 08456 448803 Email info@mhgheating.co.uk Web www.mhgheating.co.uk

010114

2.1 Appliance Warranties

All MHG appliances enjoy a full 24 month warranty as detailed in our terms and conditions.

The guarantee period shall begin on the day of commissioning, or at latest 3 months after delivery

has been made.

The customer shall only be able to claim against MHG under guarantee if the commissioning of

the object of delivery has been carried out by MHG staff or the authorised supplier, if the customer

has followed MHG's instructions relating to the treatment and maintenance of the object of

delivery, and if no replacement parts of outside origin have been fitted.

Parts subject to wear such as ignition electrodes, seals etc. are strictly excluded from the

guarantee.”

In addition to the above warranties, the Primary Heat Exchangers carry a 60 month guarantee

against manufacturing or material defect.

Supplied Components

All ProCons are supplied with the following components.

QAC 34 Outside Air Sensor. (To activate direct on boiler weather compensation.)

Wall Mounting bracket and fixing kit.

Condensate outlet adapter. (To convert ¾” BPS to 22mm plastic waste.)

Bleed key & heat exchanger venting hose.

Condensate syphon flushing hose. (To be attached to the heat exchanger and flue waste pipes and

flushed with clean water.)

MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR

Telephone 08456 448802 Fax 08456 448803 Email info@mhgheating.co.uk Web www.mhgheating.co.uk

010114

3.0 Dimensions. 16 –47 Boilers

Legend

Cable Entry Grommets

Hot Water Primary Return 22mm (HS Models)

Cold Water Inlet 22mm (S Models)

Heating Flow 22mm (All Models)

Heating Return 22mm (All Models)

Hot Water Primary Flow 22mm (HS Models)

Hot Water Outlet 22mm (S Models)

Condensate Outlet ¾” BSP Plastic

Gas Inlet 22mm

7.1

Condensate Cleanout Connection ¾” Cap

MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR

Telephone 08456 448802 Fax 08456 448803 Email info@mhgheating.co.uk Web www.mhgheating.co.uk

010114

3.1 Dimensions.75 Boiler

Legend

Condensate Cleanout Connection ¾” Cap

Heating Return 1 ¼”

Condensate Outlet ¾” BSP Plastic

Gas Supply inlet ¾”

Heating Flow 1 ¼”

Cable Entry Grommets

MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR

Telephone 08456 448802 Fax 08456 448803 Email info@mhgheating.co.uk Web www.mhgheating.co.uk

010114

3.2 Dimensions. 77 Boiler

Legend

Heating Return Connection 1 ¼”

Condensate Cleanout Connection ¾” Cap

Heating Flow Connection Option 1 ¼”

Gas Inlet ¾”

Condensate Outlet ¾” BSP Plastic

Cable Entry Grommets

**Please note that the flexible flow connection can be rerouted to the top of the boiler if

required.**

MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR

Telephone 08456 448802 Fax 08456 448803 Email info@mhgheating.co.uk Web www.mhgheating.co.uk

010114

3.3 Dimensions HS + Calorifier Below (Additional information available from the website www.mhgheating.co.uk)

Legend

Hot water Primary Flow 1”

Hot Water Primary Return 1”

Hot Water Secondary Outlet ¾”

120 Litre Calorifier

Hot Water Secondary Return ½”

Pipework Cover

Cold Water Secondary Inlet ¾”

Calorifier Cover

3.3 Dimensions HS + Calorifier Adjacent (Additional information available from the website

www.mhgheating.co.uk)

Legend

Hot Water Primary Return ¾”

Hot water Primary Flow ¾”

Hot Water Secondary Outlet ¾”

60 Litre Calorifier

Cold Water Secondary Inlet ¾”

Calorifier Cover

Hot Water Secondary Return ½”

Pipework Cover

MHG Heating Ltd Unit 4 Epsom Downs Metro Centre, Waterfield, Tadworth, Surrey KT20 5LR

Telephone 08456 448802 Fax 08456 448803 Email info@mhgheating.co.uk Web www.mhgheating.co.uk

010114

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